Effect of Radial Clearance on Stress and Strain Distribution in the Astral Deep Drawing

Jawad, Waleed K.; Ekal, Ali Tumah

doi:10.30684/etj.37.8a.4

Cited by 7 publications

(5 citation statements)

References 4 publications

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“…Lastly, the results of the DD process of the existing FEA have been verified with numerous formerly researched studies in the literature, and it appears that the DD process is close to it. 17,18,20,22 The heptagonal cup of the DD process FEA is illustrated in Figure 5(b).…”

Section: Finite Element Analysis (Fea)mentioning

confidence: 99%

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Radial clearance influence on strain and stress distribution of the polygonal shape deep-drawing operation

Mukhirmesh,

Dalfi,

Al-Abedy

2024

Advances in Mechanical Engineering

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In the existing research, polygonal -shaped dies were manufactured based on the dimensions of the design. These dies were then assembled on the deep-drawing device to create polygonal cups (specifically heptagonal cups) for conducting experimental work tests. The process was achieved via a deep-drawing operation to create heptagonal cups with dimensions (diameter D = 40mm and height L = 31.5 mm). For both experimental work and finite element analysis, the cups of heptagonal shapes were formed from flat circular blanks of Low Carbon Steel (thickness to = 0.7 mm) and diameter D = 80mm. A commercial software program, ANSYS, was employed to perform this finite element analysis. The research aims to study the effect of different radial clearance ( RC = 1.1 to,1.2 to, and 1.3 to) between die and punch for heptagonal shape DD operations on the forming load, the height of the cup, thickness distribution, strain and stress distribution along the cup wall (side-wall and wall curvature). The analysis outcomes indicate that the maximum forming force was 51.250 kN with the wall curvature, the maximum effective strain was 0.8231, and the maximum stress was 676 MPa when the [Formula: see text]1.1 to). Additionally, the squeezing process in the mug wall occurred with [Formula: see text]1.1 to).

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Section: Finite Element Analysis (Fea)mentioning

confidence: 99%

“…The forming force was also reduced by 24.45%. Jawad and Ikal 20 researched the impact of different radial clearances on stress and strain distribution in star-shaped cups made through the DD process was investigated. Three clearances (1.1, 1.2, and 1.3) between the die and punch were used.…”

Section: Introductionmentioning

confidence: 99%

Radial clearance influence on strain and stress distribution of the polygonal shape deep-drawing operation

Mukhirmesh,

Dalfi,

Al-Abedy

2024

Advances in Mechanical Engineering

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“…Figure 5 displays the punches and dies utilized in the experimental investigation. The Maximum Drawing Force (MDF) required to draw the component was calculated by [19]:…”

Section: A Deep Drawing Tool Designmentioning

confidence: 99%

“…BHF is typically around the one-third of the drawing force, as suggested in [17]. Equation (2) [19] can also be used to define the BHF:…”

Section: A Deep Drawing Tool Designmentioning

confidence: 99%

Experimental and Analytical Investigation of the Ceep Drawing Process for producing Pentacle Cups

Mohsein,

Jawad,

Abed

2024

Eng. Technol. Appl. Sci. Res.

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Sheet metal forming is a critical process in modern manufacturing, used to create both finished and semi-finished products. In this industry, there is an increasing demand for fast and cost-effective manufacturing and modification of dies. Therefore, improving theoretical and experimental engineering approaches to reduce manufacturing costs and lead-time between design and production is essential. The development of numerical methods has made Finite Element Analysis (FEA) a valuable tool for predicting product deformation. This study used three forming methods to create a pentacle cup from a low-carbon steel sheet (1008-AISI) with a thickness of 0.7 mm and a diameter of 80 mm. ANSYS Workbench 3-D modeling software was utilized to simulate the drawing procedures. The resulting product's wall thickness and strain were measured and graphed to demonstrate the impact of the different forming methods. The first method involved direct formation by drawing a circular blank metal into a pentacle shape. The second method involved redrawing a cylindrical cup into a pentagonal cup, while the third method entailed converting a pentagonal cup into a pentacle cup. The results showed that the second forming method produced the highest maximum punch load reaching approximately 42.24 kN in experimental testing and 36.66 kN in Finite Element Modeling (FEM), exceeding that of the third forming method. The maximum thinning at cup curvature was observed in the pentacle cup created by the second method, particularly in the major and minor areas, and was more pronounced than in the pentacle cups produced by the third forming method. Ultimately, the third forming method was identified as the optimal technique for producing a pentacle cup with less thinning at the cup curvature and a more uniform distribution of thickness and strain. Overall, this study highlights the importance of advancements in theoretical and experimental engineering approaches to reduce manufacturing costs and improve the efficiency of the sheet metal forming process. The findings from this study can lead to the development of optimal forming techniques for creating high-quality products.

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“…When a die has a clearance of (1mm) and blank thickness (1mm), the part that is created has the greatest ability to be formed, and there are no wrinkles on the part, but it has a smaller earring. Waleed and Ali [6] studied the effect of radial clearance (RC) on the stress and strain distribution during astral deep drawing. There are three different radial clearance values employed in this analysis (1.1t o , 1.2t o , and 1.3t o ), and the findings indicated that the highest drawing force value was 55kN when the clearance value was 1.1mm.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Theoretical Analysis to Produce Pentagonal Cup in Deep Drawing Process

Mohsen

Jawad

Abed

2023

ETJ

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The manufacturing industry heavily relies on deep drawing due to its remarkable ability to produce intricate symmetrical and asymmetrical shapes with accuracy and efficiency. This research aimed to create a deep drawing tool capable of producing a pentagonal cup measuring 41mm in diameter and 30mm in height. This was achieved by conducting numerical simulations and experimental tests using two different methods. The first method involved converting an 80mm diameter circular blank into a pentagonal cup through a drawing operation, while the second method involved redrawing a cylindrical cup into a pentagonal shape. The study also analyzed the impact of these methods on the drawing load, stress/strain distributions, and thickness distributions. The finite element method software, ANSYS 20, was employed for numerical simulations. The results showed that the first method had a significantly higher punch load than the second method. However, the pentagonal cup produced using the first method had a greater thickness reduction towards the cup wall curvature compared to those produced using the second method. Therefore, the second method was considered ideal for manufacturing a pentagonal cup because it resulted in a lower degree of thinning at the cup curvature and a more uniform distribution of thickness, stress, and strain. In conclusion, this research highlights the importance of deep drawing in the manufacturing industry and emphasizes the need to choose the appropriate forming method to achieve optimal results.

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Effect of Radial Clearance on Stress and Strain Distribution in the Astral Deep Drawing

Cited by 7 publications

References 4 publications

Radial clearance influence on strain and stress distribution of the polygonal shape deep-drawing operation

Radial clearance influence on strain and stress distribution of the polygonal shape deep-drawing operation

Experimental and Analytical Investigation of the Ceep Drawing Process for producing Pentacle Cups

Experimental and Theoretical Analysis to Produce Pentagonal Cup in Deep Drawing Process

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